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US 8,715,437 B2Granted
Composite foam product
AssigneeNovation Iq LLC
InventorMichel Marc
Life of this patent
Estimating the term…
Abstract
A composite foam product comprising a foam core surrounded by a gas-impermeable film. The gas-impermeable film retains the gas formed from the blowing agent so that the pressure inside the foam core is above ambient pressures.
Claims36
A process for forming a composite foam product comprising:
- forming a foam core from a foamable material and a blowing agent, said foam core having a plurality of cells therein, said plurality of cells retaining a gas from said blowing agent therein at a pressure above an ambient pressure, and said foam core having an exterior surface;
- and then
- placing a first gas impermeable film in a molding cavity;
- placing said foam core in said molding cavity;
- placing a second gas impermeable film over said foam core in said molding cavity;
- adhering the first and second gas impermeable films to said exterior surface of said foam core by heating the first and second gas impermeable films to their softening temperatures, wherein the first and second gas impermeable films are adhered to substantially all of the exterior surface of the foam core such that said gas from said blowing agent is retained in said cells of said foam core at said pressure above said ambient pressure;
- wherein the process further comprises applying a first adhesive between said foam core and said first gas impermeable film and applying a second adhesive between said foam core and said second gas impermeable film.
4 more elements
A process for forming a composite foam product comprising:
- providing a flow molding apparatus having an upper mold and a bottom mold that define a molding cavity therebetween and also having a movable diaphragm disposed in said molding cavity;
- positioning a first gas impermeable film on said bottom mold in said molding cavity;
- placing a foaming mixture comprising a foamable material and a blowing agent on said gas impermeable film in said molding cavity;
- placing a second gas impermeable film over said foaming mixture in said molding cavity;
- and
- deflecting said moveable diaphragm downwards so as to expel air from said molding cavity;
- heating said foaming mixture and said first and second gas-impermeable films in said molding cavity, whereby said moveable diaphragm is deflected upwards as said foaming mixture expands to form a foam core having an exterior surface and a plurality of cells therein, said plurality of cells having a gas from said blowing agent therein at a pressure above an ambient pressure;
- and whereby said first and second gas-impermeable films are adhered to said exterior surface of said foam core.
5 more elements
A process for forming a composite foam product comprising:
- providing a flow molding apparatus having a first mold and a second mold that define a molding cavity and also having a movable diaphragm disposed in said molding cavity;
- positioning a gas impermeable film in said molding cavity;
- placing a foaming mixture comprising a foamable material and a blowing agent in said molding cavity;
- deflecting said moveable diaphragm downwards so as to expel air from said molding cavity;
- heating said foaming mixture and said gas impermeable film in said molding cavity, whereby said moveable diaphragm is deflected upwards as said foaming mixture expands to form a foam core having an exterior surface and a plurality of cells therein, said plurality of cells having a gas from said blowing agent therein at a pressure above an ambient pressure;
- and
- whereby said gas impermeable film is adhered to said foam core.
4 more elements
Dependencies are inferred from the claim text.